Cylinder head removal (4JJ3 without DPD)

1. Component views

Cylinder head

Part name

  1. Cylinder head
  2. Gear case nut
  3. Gear case bolt
  4. Cylinder head bolt
  5. Cylinder head gasket
  6. Timing gear case gasket

Tightening torque

2: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4-1: 70 N・m { 7.1 kgf・m / 52 lb・ft }

4-2: 70 N・m { 7.1 kgf・m / 52 lb・ft }

4-3: 60 to 75 °

4-4: 60 to 75 °

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3) Raise the vehicle.

3. Engine hood removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors engine hood removal".

4. Engine oil drain

1) Remove the drain plug from the oil pan, and drain the engine oil to a pan.

2) Install the drain plug to the oil pan.

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }

Caution

  • Do not reuse the gasket.
  • Do not forget to tighten the drain plug.

5. Wiper linkage removal

Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage removal".

6. Cowl panel removal

1) Remove the cowl panel from vehicle.

7. Turbocharger removal

Refer to "1.Engine 1F.Induction(4JJ3 without DPD) Turbocharger removal".

8. Battery removal

1) Disconnect the battery ground cable from the frame.

2) Disconnect the battery cable from the battery.

3) Remove the battery bracket from the frame.

4) Remove the battery from vehicle.

Legend

  1. Battery cable
  2. Battery bracket
  3. Battery ground cable

9. Radiator upper hose removal

1) Remove the radiator upper hose from the thermostat and radiator.

Legend

  1. Radiator upper hose

10. Radiator reserve tank removal

1) Disconnect the radiator reserve tank hose from the radiator.

2) Remove the radiator reserve tank from the fan guide.

11. Fan guide removal

1) Remove the fan shroud from the fan guide.

2) Remove the fan guide from the radiator.

Legend

  1. Fan shroud
  2. Fan guide
  3. Radiator

12. Cooling fan removal

1) Remove the cooling fan and cooling fan clutch as a set from the water pump.

2) Remove the fan pulley from the water pump.

13. A/C compressor drive belt removal

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the A/C compressor drive belt from the following parts.

  • Tension pulley
  • A/C compressor
  • Crankshaft pulley

Legend

  1. Lock nut
  2. Adjust bolt
  3. A/C compressor drive belt

14. Cooling fan belt removal

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the cooling fan belt from the following parts.

  • Fan pulley
  • Generator
  • Crankshaft pulley

Legend

  1. Adjust bolt
  2. Cooling fan belt
  3. Lock nut

15. Generator removal

1) Disconnect the B-terminal from the generator.

2) Disconnect the connector from the generator.

3) Remove the upper bracket from the generator and timing gear case.

4) Remove the generator from the lower bracket.

16. Intake air duct removal

1) Disconnect the connector from the boost pressure sensor.

2) Disconnect the air intake hose from the intercooler.

3) Remove the intake air duct from the intake throttle valve.

17. A/C compressor disconnect

1) Disconnect the A/C compressor from the A/C compressor bracket.

Legend

  1. A/C compressor bracket
  2. A/C compressor

18. A/C compressor bracket removal

1) Remove the A/C compressor bracket from the cylinder head.

19. Oil level gauge guide tube removal

1) Remove the oil level gauge from the oil level gauge guide tube.

2) Remove the oil level gauge guide tube from the crankcase.

Caution

  • Do not reuse the O-ring.

20. Air duct bracket removal

1) Remove the air duct bracket from the cylinder head cover.

21. Fuel leak-off hose removal

1) Disconnect the connector from the injector.

2) Remove the fuel leak-off hose from the leak-off pipe.

Legend

  1. Fuel leak-off hose
  2. Injector connector

3) Remove the injector leak-off pipe from the injector.

Caution

  • Do not reuse the injector leak-off pipe or clip.

Legend

  1. Injector leak-off pipe
  2. Clip

22. Cylinder head cover removal

1) Disconnect the PCV hose from the cylinder head cover.

2) Disconnect the harness clip from the cylinder head cover.

RHD

LHD

3) Remove the harness bracket from the cylinder head cover.

4) Remove the cylinder head cover from the cylinder head.

Caution

  • Do not reuse the gasket.

5) Remove the oil seal from the lower side of the cylinder head cover.

23. Fuel hose disconnect

1) Disconnect the fuel feed hose from the fuel supply pump.

2) Disconnect the fuel return hose from the fuel leak-off pipe.

Legend

  1. Fuel feed hose
  2. Fuel return hose

24. Swirl control solenoid valve removal

1) Disconnect the connector from the swirl control solenoid valve.

2) Disconnect the vacuum hose from swirl control solenoid valve.

3) Remove the swirl control solenoid valve and bracket as a set from the inlet manifold.

Legend

  1. Swirl control solenoid valve

25. Leak-off pipe removal

1) Remove the harness bracket from the inlet manifold.

Legend

  1. Harness bracket

2) Disconnect the 3 vacuum hoses from the vacuum pipe.

3) Disconnect the 2 leak-off hoses from the leak-off pipe.

4) Remove the leak-off pipe from the inlet manifold.

Legend

  1. Leak-off hose (Injector side)
  2. Leak-off pipe
  3. Leak-off hose (Supply pump side)
  4. Vacuum hose (Swirl control valve side)
  5. Vacuum hose (Vacuum pump side)

26. Injection pipe removal

1) Remove the clip from the injection pipe.

2) Remove the injection pipes from the injector and common rail (fuel rail).

Caution

  • Do not reuse the injection pipe.

Legend

  1. Injection pipe
  2. Clip

27. Injector removal

1) Remove the injector clamp from the injector.

2) Remove the injector from the cylinder head.

Note

  • If it is difficult to remove the injector, use a remover.
  • Store the removed injectors with the cylinder numbers attached.

Caution

  • Cover the exposed portion to prevent foreign material from getting into the fuel system.
  • Do not damage the injector nozzle.
  • Absolutely never touch the injector solenoids because that can hinder their performance or cause damage.

3) Remove the gasket from the injector.

4) Remove the O-ring from the injector.

Caution

  • Do not reuse the following parts.
  • Clip
  • O-ring
  • Gasket

Legend

  1. Injector
  2. Leak-off pipe
  3. Clip
  4. O-ring
  5. Gasket

28. Tension pulley removal

1) Remove the tension pulley from the cylinder head.

29. Water pipe removal

1) Remove the water pipe from the following parts.

  • Thermostat
  • Cylinder head
  • Turbocharger

30. Radiator lower hose disconnect

1) Disconnect the radiator lower hose from the water intake pipe.

Legend

  1. Radiator lower hose

31. Water intake pipe removal

1) Remove the water intake pipe and water hose as a set from the oil filter and oil cooler.

Caution

  • Do not reuse the gasket.

32. Intake throttle valve removal

1) Disconnect the connector from the intake throttle valve.

2) Remove the following parts from the inlet manifold.

  • Air duct bracket
  • Intake throttle valve
  • Gasket

Caution

  • Do not reuse the gasket.

Legend

  1. Air duct bracket
  2. Intake throttle valve
  3. Gasket

33. EGR valve removal

1) Remove the EGR valve and gasket from the inlet manifold.

Caution

  • Do not reuse the gasket.

34. Thermostat removal

1) Disconnect the water hose from the water outlet pipe.

2) Remove the thermostat from the thermostat housing.

Caution

  • Do not damage the thermostat.

Legend

  1. Thermostat
  2. Jiggle valve

35. Glow plug removal

1) Remove the glow plug terminal and glow plug connector from the glow plug.

Legend

  1. Glow plug terminal
  2. Glow plug connector

2) Remove the glow plug from the cylinder head.

Legend

  1. Glow plug

36. Baffle plate removal

1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top dead center.

Legend

  1. Alignment mark of No. 1 cylinder compression top dead center

2) Remove the baffle plate from the cylinder head.

37. Timing chain upper cover removal

1) Disconnect the connector from the CMP sensor.

Legend

  1. CMP sensor

2) Remove the timing chain upper cover from the cylinder head.

Legend

  1. Timing chain upper cover

38. Timing chain lower cover removal

1) Remove the noise cover from the timing chain lower cover.

2) Remove the timing chain lower cover from the gear case cover.

39. Timing chain removal

1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top dead center.

Legend

  1. Top dead center alignment mark on the gear case cover side
  2. Crankshaft pulley side top dead center alignment mark

2) Align the marks of the camshaft upper bracket and camshaft.

Legend

  1. Alignment mark

3) Remove the oil feed pipe from the timing chain tensioner.

Caution

  • Do not reuse the gasket.

4) Remove the timing chain tensioner and gasket from the cylinder head.

Caution

  • Do not reuse the gasket.

Legend

  1. Oil feed pipe
  2. Timing chain tensioner
  3. Gasket

5) Remove the timing chain lever pivot from the timing chain tension lever.

6) Remove the idle gear D shaft bolt and sleeve from idle gear D and sprocket.

7) Remove the timing chain and sprocket as a set from idle gear D.

Legend

  1. Idle gear D shaft bolt
  2. Sleeve
  3. Sprocket

8) Remove the timing chain from the supply pump sprocket by lowering the timing chain and sprocket.

9) Take the timing chain tension lever out from the cylinder head.

10) Remove the timing chain guide from the cylinder head and cylinder block.

Legend

  1. Timing chain guide bolt

40. Camshaftbracket removal

1) Use the M5 lock bolt to secure the camshaft gear.

2) Remove the following parts as a set from the cylinder head.

  • Camshaft bracket
  • Rocker arm shaft
  • Camshaft
  • Idle gear D

Legend

  1. Camshaft bracket
  2. Cylinder head

41. Cylinder head removal

1) Install special tool to the cylinder head.


SST: 5-8840-2886-0 - rear engine hanger

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the wire to the engine hanger and hoist.

3) Remove the nuts and bolts from between cylinder head and timing gear case.

Legend

  1. Nut
  2. Bolt
  3. Nut

4) Loosen the cylinder head bolts in the order shown in the diagram.

Caution

  • Do not reuse the cylinder head bolts.

5) Remove the cylinder head from the cylinder block.

6) Remove the cylinder head gasket and timing gear case gasket from the cylinder head.

Caution

  • Do not reuse the cylinder head gasket and timing gear case gasket.
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